Method of producing an inlay puzzle

ABSTRACT

THE STOCK FROM WHICH PUZZLE PIECES FRAME ARE CUT HAS THIN PICTURE AND PLASTIC FILM PILES LAMINATED TO ITS OUTER FACE. STRONG ADHESIVE HOLDS THE PICTURE TO THE STOCK BUT &#34;LOW-TAC&#34; ADHESIVE IS USED FOR THE FILM PLY. WORKING FROM THE REAR FACE OF THE STOCK WITH A HIGH-SPEED ROUTER OF SMALL SECTION, PUZZLE PIECES AND THE PICTURES THEREON ARE SEVERED FROM EACH OTHER AND FROM THE FRAME LEAVING   THEN STILL ATTACHED TO THE FILM. THE BACKBOARD IS THEN ADHESIVELY ATTACHED TO THE FRAME WITHOUT ATTACHMENT TO THE PUZZLE PIECES. REMOVAL OF THE PLASTIC FILM BY THE CUSTOMER LEAVES THE PUZZLE PIECES FREE IN THE FRAME.

Oct. '26, 1971 c. P. CONNOR 3,615,094

METHOD OF PRODUCING AN INLAY PUZZLE Filed May 11, 1970 United States Patent Oflice 3,615,094 Patented Oct. 26, 1971 3,615,094 METHOD OF PRODUCING AN INLAY PUZZLE Gordon P. Connor, Wausau, Wis., assignor to Connor Forest Industries, Wausau, Wis. Filed May 11, 1970, Ser. No. 36,338 Int. Cl. A63f 9/10 US. Cl. 273-157 R 4 Claims ABSTRACT OF THE DISCLOSURE The stock from which puzzle pieces and frame are cut has thin picture and plastic film plies laminated to its outer face. Strong adhesive holds the picture to the stock but low-tac adhesive is used for the film ply. Working from the rear face of the stock with a high-speed router of small section, the puzzle pieces and the pictures thereon are severed from each other and from the frame leaving them still attached to the film. The backboard is then adhesively attached to the frame without attachment to the puzzle pieces. Removal of the plastic film by the customer leaves the puzzle pieces free in the frame.

BACKGROUND OF INVENTION In the past, inlay puzzles have commonly been made by relatively expensive procedures which are made unnecessary when the puzzle pieces are severed from the frame prior to attachment of the backboard.

SUM MARY OF INVENTION By completely severing the puzzle pieces from each other and the frame before the backboard is attached to the frame, and leaving them releasably anchored only by removable film, it is readily possible to separate the puzzle pieces for the first time when they are in the hands of the customer, leaving the entire puzzle completely assembled for purposes of sale. The picture is fully visible, assuming the film to be transparent.

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a view in perspective showing the severance of the puzzle pieces and frame, working from the back side of the puzzle stock.

FIG. 2 is a greatly enlarged fragmentary detail view in cross section showing the router penetrating the puzzle stock and the picture sheet and leaving the plastic film as a temporary connection.

FIG. 3 is a further enlarged fragmentary detail view in cross section showing application of the backboard across the frame and the inverted puzzle pieces severed by the router.

FIG. 4 is a view in perspective showing the step of stripping off the film.

DETAILED DESCRIPTION The invention is not at all concerned with materials. For convenience, reference is made to boards and sheets of paper and of plastic but it will be understood that the choice of materials is largely optional.

A sheet 6 of the stock from which the frame and puzzle pieces are to be cut has a picture sheet permanently attached to its face as by adhesive 10. The stock will normally be wood fiber board or particle board but may be cardboard or plastic. The picture which has its parts on the puzzle pieces is ordinarily printed on paper but may be printed on plastic or directly on the puzzle pieces. The adhesive is referred to as permanent to differentiate it from the low-tac release type adhesive mentioned as a means of holding the removable film. Overlying the picture sheet is a preferably transparent film 12 of synthetic resin strippa'bly held thereto as by a low-tac release type adhesive 14.

As one alternative, the picture sheet may have a varnish coating and the clear acetate film may be provided with a special adhesive which will not be permanent in nature. As a second alternative, the picture sheet may have a coating with a release agent in it so that the film, regardless of adhesive used, if any, can be removed preliminary to use.

Using in a high speed router a tapered bit 16 as thin as is practicable, the puzzle sections 18 are cut from each other and from the frame 20. The penetration of the router bit should be such, as shown in FIG. 2, that it completely se-vers the stock 6 and the picture sheet 8. It is not required to penetrate the film 12 but may penetrate slightly to make sure that the pieces are severed. Following this operation, the puzzle pieces, each with its own section of the picture, have been cut from each other and from the frame but are fixed within the frame by the plastic film.

The backboard 24 is now applied across the face 26 of the stock 6 but is adhesively attached only to the frame 20. The puzzle pieces remain free.

The product is now ready for sale. The user can readily strip the film 12 from the puzzle pieces, thus permitting them to be dumped from the frame and mingled preliminary to re-assembly therein.

An incidental advantage of the invention consists in the fact that the puzzle pieces are slightly reduced in area by the router bit, thus giving a moderate clearance which makes the puzzle easier for a child to assemble.

I claim:

1. A method of producing an inlay puzzle, which method consists in cementing a film to one side of a sheet of stock, cutting completely through said stock upon lines terminating short of the side margins of said stock to form a marginal frame and to sever puzzle pieces from the surrounding frame, the severance extending through the stock and to the film, and attaching a backboard to said frame on the side opposite the side to which the film is cemented and in a position underlying said pieces, the film being subsequently stripped from the puzzle pieces following severance thereof from each other and from the frame.

2. A method of producing an inlay puzzle, said method comprising successive lamination of a picture ply and a film ply to a sheet of stock from which puzzle pieces are to be cut, routing through said stock and said picture ply narrow channels of such depth and extent as to sever puzzle pieces from the stock, the said channels terminating short of the margin of said stock whereby to leave "a marginal frame, the several puzzle pieces being completely severed from each other and from the frame, and portions of said picture mounted on the puzzle sections being likewise severed from each other and from the frame, the routing step being too shallow to sever said film ply between puzzle pieces, thereafter covering the frame and the severed puzzle sections with a baseboard and adhesively connecting said board to said frame independently of said puzzle pieces.

3. A method according to claim 2 in which the baseboard is applied over a surface of said stock opposite that to which the film ply is laminated, and the film is ultimately stripped from the puzzle pieces leaving such pieces free and exposed to being dumped from the frame.

4. A method according to claim 3 in which the lamination of the picture ply and the film ply is achieved by means of a release coating which temporarily holds the plies in laminated assembly while readily facilitating their separation.

References Cited UNITED STATES PATENTS Douglas 273-157 R UX 4 FOREIGN PATENTS 216,842 8/1958 Australia 273-157 R 526,954 6/1956 Canada 273-157 R 5 ANTON O. OECHSLE, Primary Examiner U.S. C1. X.R. 

